revision of specification / str tubes with components for
TRANSCRIPT
SCHEDULE OF TECHNICAL REQUREMENNTS FOR TRACTION MOTOR END FITTINGS
OF BG DIESEL ELECTRIC LOCOMOTIVESItem Name: Schedule of Technical
requirement for Traction Motor Roller Suspension Bearing
Tubes with components for BG Diesel –Electric Locomotives (ALCo & HHP Locos) and
DEMUS.
STR No. : MP.STR.EM-01.01.12((Revision-02), July’2020.
1. RDSO is reviewing the specification/STR to cater to the latest technological developments in
the field, modify clauses not relevant in the present context and making them more enabling
with focus on functional requirements.
2. It is requested that your comments / suggestions with regard to improvements /modifications
in specification / STR of the above mentioned item may be submitted in the following format
along with the justification for the changes required.
Part A: Basic Information
5 Address for Correspondence
6 Contact No.
7 Email ID
8 Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item
9 Whether any technical document/Report/Study to support suggested changes is available / enclosed for better appreciation
Part B: Comments / Suggestions on the specification
SN Clause No. of RDSO STR/ Spec
Clause, as it exists in RDSO STR/ Spec
Clause , as it should read after incorporation of comments /suggestions in the RDSO Spec / STR
Justification for changes
Comments may be sent to following address within one month from the date of publication on
rdso.indianrailways.gov.in
Manak Nagar, Lucknow – 226011
GOVERNMENT OF INDIA MINISTRY OF RAILWAYS
( )
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO & HHP LOCOS) & DEMUS.
...-..(-),-
STR.NO.MP.STR.EM-01.01.12 (Revision -02),July 2020
ekud uxj] y[kuÅ - 226 011
RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226 011
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 2 of 18
LIST OF AMENDMENTS
No
STR No. MP.STR.EM-01.01.12(Rev-02) of July 2020
1
Clause 5.1 IS:1030,IS:1387,IS:2062,
IS:1757,IS: 3739 & IS: 4897
ASTM A370/05, ASTM A388,
Latest version of amendment &
& BS:1486 Latest version of
added
added
Latest version added.
14 Clause 20 Preference to make in India shall
apply added
added (Vendor changes in
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 3 of 18
-- AMENDMENT HISTORY 1
4.0 QUALITY CONTROL ORGANIZATION 4
5.0 GOVERNING SPECIFICATIONS 4-5
6.0 INCOMING MATERIAL 6
9.0 QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN 9
10.0 CHEMICAL COMPOSITION 10
11.0 MATERIAL SPECIFICATION 10
14.0 INSPECTION 11
16.0 MECHANICAL TESTS 12
18.0 TEST CERTIFICATES 13
-- MACHINERY & PLANT (M&P) FOR MANUFACTURING (ANNEXURE-I) 14
-- LIST OF MEASURING MACHINES & INSTRUMENTS (ANNEXURE-II) 15
-- LIST OF TESTING FACILITIES (ANNEXURE-III) 16
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 4 of 18
REVISED SCHEDULE OF TECHNICAL REQUIREMENTS FOR
TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL- ELECTRIC LOCOMOTIVES (ALCO & HHP BOTH) AND DEMUs
1.0 SCOPE:
The Motor Suspension Unit (MSU) tubes are vital parts of traction motors used on Alco and HHP diesel electric locomotives as well as DEMU of Indian Railways. These components are procured by DLW, DMW and Zonal Railways from RDSO approved sources as per DLW, DMW & BHEL/CGL drawings. In addition, a number of assembly components are also procured as per DLW, DMW & BHEL/CGL drawings. The schedule of technical requirement (STR) mentioned hereunder is being issued to serve as a guide to manufacturers and shall be read in conjunction with the relevant drawings. The firms shall satisfy themselves to having complied with, all the requirements of the drawings and STR. Approval shall be granted to a firm that has the capability to supply fully machined suspension tube as per the STR. ( This STR supersedes earlier issued RDSOs STR No. MP.01.01.12Rev-01) July 2019)
2.0 GENERAL REQUIREMENTS:
2.1 The firm shall have valid ISO-9001-2015 certification issued by an approved agency with the activity desired clearly mentioned in the scope of certification. The firm shall have a Quality Manual indicating the extent of control over production.
2.2 A system of regular submission of rejection details of material giving rejection rate, cause of rejection, corrective action taken etc. on quarterly basis shall be followed by the firm.
2.3 The firm shall have a system of documentation with respect to rejection at customer end, warranty replacement and failure of item supplied by them during service.
2.4 The firm shall have a system of recording the plant, machinery and control equipments remaining out of service, nature of repairs done etc.
2.5 The testing and measuring equipment shall be duly calibrated and the validity of calibration shall be current and verified by physically checking the calibration certificate issued by the Calibration Agency from where it was calibrated.
2.6 The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage.
2.7 At the time of application, the firm must submit clause wise compliance of this STR.
3.0 QUALITY ASSURANCE PLAN (QAP):
The firm shall prepare a Quality Assurance Plan (QAP) for all items for which approval is sought and submit the same as a part of compliance of this STR. The
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 5 of 18
QAP shall be a comprehensive document covering the following aspects including all the parameters in accordance with ISO Document No. QM-RF-8.1-3, Version No. 1.0 or latest - Guidelines for preparing QAP during registration. (i) Details of Quality Control Organization of the firm along with key personnel
engaged in the QC function. (ii) Quality Assurance Process of incoming materials used for the subject items. (iii) Process Flow Chart indicating process of manufacture of an individual product
or for a family of products, if the process is same. (iv) Quality Assurance System – Inspection & Testing Plan including stage
inspection. (v) Calibration scheme and status of calibration of equipments used in the quality
process.
Details of the above aspects are described in the following paragraphs. The QAP shall be approved by RDSO and shall form basis of approval process.
3.1 Firm shall have to declare details of the manufacturing operations to be conducted
in house or by outside agencies. Details of the outside agencies shall be indicated and prior approval shall be taken from RDSO, which reserves the right to inspect these firms also.
A general format for guidance is given below:
Product / Name of the process and details of machine used indicating their capacities / accuracy limit
Acceptance limit of the parameters to be inspected during different operations of MSU Tube and components
Standards followed for acceptance of the test parameters
Sample size & its frequency of inspection
Format no. for recording for traceability
Action taken on rejection, if any
Calibration scheme and status of calibration of equipments used in the quality control process
4.0 QUALITY CONTROL ORGANIZATION: 4.1 The complete organizational setup of the quality control key personnel and officials
along with their qualification and experience shall be furnished. 4.2 The Quality Control Organization shall be headed by a senior level official having
adequate technical qualification who shall directly report to plant in-charge.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 6 of 18
5.0 GOVERNING SPECIFICATIONS:
The latest revisions as applicable to the specification referred below shall be followed.
5.1 For materials: (i) IS: 1030-1998 (5th Rev.) Reaffirmed 2017 or latest version - “Carbon steel castings
for general engineering purposes- specification”. (ii) IS: 1387-1993 (Second Rev.) Reaffirmed 2018 or latest version - “General
requirements for the supply of metallurgical materials”. (iii) IS: 2062-1999 2011 (7th Revision),Reaffirmed 2018 or latest version Steel for general
structural purposes – Specification (Fifth Rev.). (iv) IS: 2269- 1995,2006(5th Revision ) Reaffirmed 2016 or latest version Specification for
Hexagon socket head screws. (v) IS: 5517-1993(2nd Revision), Reaffirmed 2019 or latest version Steels for hardening
and tempering – Specification. (vi) IS: 12117 – 1996(1st Revision) Reaffirmed 2017 or latest version : Norms for
classification of Steel Foundries for quality assurance (First Rev.), Feb.2002. (vii) ISO: 9001- 2000 2015: Purchasing Procedure. (viii) BS: 1486 Part-II 1961( or latest version) for Zinc Plated Grease Nipple. (ix) ASTM A513 – 20 or Latest version Steel Tubing. (x) ASTM A519-17 or Latest version – Hot finished seamless tubing. 5.2 For tests: (i) IS: 1500(Part-1)(5th Revision )1983 2019or latest version „Method for Brinell
hardness test for metallic materials (Second revision). (ii) IS: 1599 - 1985 (Second Rev.) 4th revision 2019 or latest Method for bend test for
steel products other than sheet, strip, wire and tube). (iii) IS: 1608(Part-1) - 1995 (Second Rev.)(4th Revision 2018 or latest „Method for tensile
testing of steel products. (iv) IS: 1757(Part-1) - 1988 (Second Rev.) 3rd revision 2014 or latest version „Method for
Charpy Pendulum impact test (V-Notch) for metallic materials. (v) ASTM A370/05 -19 or latest version Tensile Test. (vi) ASTM A388, 2007- 19 or latest Ultrasonic Test for steel forgings. (vii) ASTM A609/A609M- 91-12 (Reapproved 2007 2018) or latest - Ultrasonic Test for
steel castings. (viii) ASTM E446 -15 or latest version - Radiography test Level- III for central portion and
Level- II for both side housing bores. 5.3 For dimensional tolerances: (i) IS: 3739-1987 (First Rev.) Reaffirmed 2018 - Dimensional tolerances for carbon and
constructional steel products. (ii) IS: 4897- 1994(3rd Revision) Reaffirmed 2017or latest version Deviations on
untoleranced dimensions and mass of steel castings.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 7 of 18
5.4 For welding:
A.I 1651- EMD welding, brazing and soldering specification. 6.0 INCOMING MATERIAL: 6.1 A complete Bill of Material (BOM) indicating all input material required for
manufacturing of the product, governing specification and their sources of supplies as approved by the firm in accordance with clause 7.4.1 of ISO:9001 (2000) shall be furnished.
6.2 Test results of incoming raw material with reference to test certificate issued by the
supplier and the results of internal tests carried out by the firm for verification shall be submitted as a part of QAP.
7.0 DIMENSIONS AND TOLERANCES:
The MSU tube and components shall conform to the respective drawings indicated for dimensions, tolerances, finish and material etc.:
7.1 List of drawings of Suspension Tube & Accessories (10 Components) for traction motor type TM 4907 application (Class of locos WDM3A & WDG3A):
Sl. no.
1/DCW/M/TM- 398, Alt- W
Casting - Carbon Steel- IS: 1030-1998 (Fifth Rev.) Reaffirmed 2017 or latest version, Gr. 280-520W.
2 Bearing Housing for TM 4907
1/DCW/M/TM- 414, Alt- Nil
3 End Cover (RWE) for TM 4907
1/DCW/M/TM- 416, Alt-Nil
Forging - IS: 5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
4 End Cover (GWE) for TM 4907
1/DCW/M/TM- 417, Alt-Nil
Forging - IS: 5517-1993 :(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
5 Abutment Piece for TM 4907
1/DCW/M/TM- 418, Alt-Nil
Forging - IS: 5517-1993 :(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
6 Enclosure for TM 4907
1/DCW/M/TM- 419, Alt-Nil
Forging - IS: 5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
7 Adjustment Washer for TM 4907
1/DCW/M/TM- 415, Alt-Nil
IS: 2062- 1999 7th revision 2011 (Reaffirmed 2016)for Steel Plate Gr- B.
8 Socket Head Screw M10 x 30 long
4/DCW/M/TM- 421, Alt-Y
IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 8 of 18
4/DCW/M/TM- 423, Alt-Y
IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version
10 Socket Head Screw M12 x 90 long
4/DCW/M/TM- 422, Alt-Y
IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version
11 Grease Nipple 4/DCW/M/TM- 420, Alt-Nil
BS: 1486 Part-II 1961 (Zinc Plated). or latest version
7.1.1 In case cast components (i.e. item at sl. no. 2 to 6 mentioned above) are chosen as
per clause 11.2, then the material shall be Carbon Steel- IS: 1030-1998 (Fifth Rev.) Reaffirmed 2017 or latest version, Gr. 280-520W.
7.1.2 Hardwares as per item no. 8 to 11 of clause 7.1 if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturers to be declared in the QAP. (If sources are not specified in the relevant drawings)
7.2 Housing Bearing Kit for HHP Loco (consisting of 11 items) as per DLW Part
No 17454499 & DGR. No. K- 1745037 Alt. ‘e’:
S. No.
Material Specifications and Tests
1 Housing Bearing Machine
17020864 / 40075563 Alt. „d or latest.
EMS 15 – Cast Steel as per casting drawing no. 40075432. A.I 1651- Weld Braze Specification mentioned in drawing no. 40075563.
2 Cap (CE) Axle Bearing Mach.
17250626 / 40086808 Alt.
„c or latest.
Material as per casting drawing no. 40076800: Casting- EMS 9 Nodular Iron and ETI 827 or Plate - MS 4361 steel.
3 Cap PE Axle Bearing Mach.
17250365 / 40076796 Alt. „b or latest.
Material as per casting drawing no. 40076797: Casting- EMS 9 Nodular Iron and ETI 827 or Plate - MS 4361 steel.
4 Seal PE 17250493 / 40076794 Alt. „b or latest.
Material as per casting drawing no. 40076795: Tubing- ASTM A519-17 or latest version or latest version Hot finished seamless tubing or Plate - MS 4361 steel.
5 Spacer CE 17087636 / 40076798 Alt. „b or latest.
ASTM A513-20 or latest version Type 5 (DOM) Steel Tubing as per drawing no. 40076798.
6 Seal 17271472 / 40076990 Alt. „b or latest.
Nitrile (Buna-N) as per drawing no. 40076990.
7 Seal 17271496 / 9084265 Alt. „c
or latest.
8 Plug 1/8 PT 17300083 / 8348617 Alt. „Ba or latest.
Steel as per drawing no. 8348617.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 9 of 18
9 Plug 3/8 PT 17300010 / 8348619 Alt. „Ba or latest.
Steel as per drawing no. 8348619.
10 Screw Hexagon Socket Head Cap
19250010- 138293 Alt. „g
or latest.
Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C37- 45 as per drawing no. 138293.
11 Screw Hexagon Socket Head Cap
19250022- 138299 Alt. „Bc
or latest.
Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C37- 45 as per drawing no. 138299.
7.2.1 Hardwares as per item no. 8 to 11 of clause 7.2, if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturer as recommended in the DLW drawing no. K- 1745037 of Housing Bearing Kit.
7.2.2 Nitrile seals as per item no. 6 & 7 of clause 7.2, if not manufactured by the supplier itself, shall be out sourced from reputed manufacturers already approved with RDSO for similar items. The sources shall be declared in the QAP.
7.3 Housing Bearing Kit for HHP Loco (consisting of 4 items) as per DLW Part
No. 17454487 & DRG. No. K-1745036 Alt. ‘c’:
S. No.
Material Specifications and Tests
„a or latest
2 Cover Assembly
17250390 / 40012764 Alt. „Ab or latest
MS 4361 Steel as per drawing no. 40012026 for Cover-GR Case AY- Mach.
3 Tube 17203510 / 40076189 Alt. „Bb or latest
ASTM A513-20 or latest version Type 5 (DOM) Steel Tubing as per drawing no. 40076189.
4 Ring 17043980 / 40076190 Alt. „Ab or latest
MS 4361 Steel as per drawing no. 40076190.
7.4 List of drawings of Suspension Tube & Accessories for traction motor type TM 4303 / C1005TM application (1400 HP DEMU):
S. No.
1 General Arrangement Axle Suspension Unit.
04391580002 (Latest) CGM/106001 (Latest) 1
2 Roller bearing suspension tube
04391580001 (Latest) CGM/106801 (Latest) 1
3 Bearing Housing 14451575001 (Latest) CGM/206803 (Latest) 1
4 Adjustment Washer 14451575002 (Latest) CGM/206805 (Latest) 1
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 10 of 18
7 Abutment Piece 14451575004 (Latest) CGM/206804 (Latest) 1
8 Enclosure 14391580001 (Latest) CGM/206801 (Latest) 1
9 Socket Head Screw (M10 x 30 Long)
44391560001 (Latest) CGM/42201 (Latest) 6
10 Socket Head Screw (M12 x 70 Long)
44391560003 (Latest) CGM/42202 (Latest) 16
11 Socket Head Screw (M30 x 110 Long)
-- CGM/406801 (Latest) 8
13 Spring Washer A30 -- CGM/32204 (Latest) 8
The manufacturer shall supply suspension tube & components for DEMU application as per the details & drawings provided above or by the purchaser. Quality control aspects of the tube & components shall conform to this STR.
7.4.1 Hardwares as per item no. 9 to 13 of clause 7.4 if not manufactured by the supplier itself, shall be out sourced from reputed brand / manufacturers to be declared in the QAP. (If sources are not specified in the relevant drawings).
8.0 PROCESS OF MANUFACTURE: 8.1 Complete process flow chart covering all steps of process of manufacture for an
individual product (or for a family of products, if the process is same) shall be clearly enlisted as a part of QAP.
8.2 The following details of machines used for all the steps of machining operations
shall be included:
Make and Model of the machine Accuracy. Details of machining operations.
8.3 Machining process shall be such that all critical dimensions are final machined on
CNC machining centers, preferably in single setting. 8.4 Details of Jigs and Fixtures used during manufacture shall be furnished along with
the manufacturing process, wherever used. 8.5 List of typical machinery & plant (M&P) required for manufacture is furnished in
Annexure- I. The list is for general guidance only and actual manufacturing operations shall be submitted and got approved by the firm as a part of QAP.
9.0 QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN:
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 11 of 18
9.1 Complete inspection and testing chart covering all steps of process of manufacture for an individual product including final inspection shall be clearly enlisted as a part of QAP.
9.2 The following details of measuring instruments / equipments / jigs / fixtures used for all the steps of measurement operations shall be included: Make and Model of the measuring equipment Accuracy Value to be measured and acceptable value range
9.3 Stage inspection detailing inspection procedure, inspection parameters and method
of testing/ test procedure including sample sizes for destructive and non-destructive testing. Record of test results of stage inspection shall be available and furnished where needed.
9.4 The list of measuring machines / instruments & testing facilities are furnished in
Annexure- II & III respectively for general guidance only. However, the specific testing and measuring instruments, gauges used by the firm will also form part of QAP, which shall be submitted and got approved by the firm.
9.5 Dimensional measurements shall be made on three-dimensional co-ordinate
measurement machines as mentioned in Annexure – II on prototype & on sample lots. Periodicity of measurement shall be as indicated in clause 17.0 (Sl. no.4) of the STR. Measurements shall be included as a part of QAP.
10.0 CHEMICAL COMPOSITION: The permissible variation in chemical composition and ladle analysis of steel shall
conform to the respective requirements given in Clause 7.0 of this STR. 11.0 MATERIAL SPECIFICATION: 11.1 General requirements relating to the supply of material shall conform to IS: 1387-
1993 (Second Rev.) Reaffirmed-2018 or latest version „General requirements for the supply of metallurgical materials, as per Clause 5.1 (ii) of this STR.
11.2 The material used for cast or forged components shall be so chosen that none of the
specified properties in this STR is compromised. 11.3 The suspension tube shall only be manufactured from castings supplied by RDSO
approved Class “A” foundries. 11.4 The suspension tube components i.e. accessories or any other components shall be
manufactured from normalized carbon steel castings or forgings as applicable & mentioned in Clause 7.0 of this STR.
11.5 In case the manufacturer proposes to supply forged suspension tube components
instead of cast components, the same can be accepted only with the prior approval
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 12 of 18
of RDSO. The forging shall be manufactured from killed steel produced by open hearth furnace, electric furnace or any other approved process.TC
11.6 Rough machining of the forgings shall be carried out in case of procurement of
forgings by the purchaser & forging shall be supplied to the dimensions specified in the drawing of rough machined components to be provided by the purchaser.
11.7 In case, finished component is procured by the purchaser, machining shall be done
in suitable sequence approved by the purchaser. 12.0 REQUIREMENT FOR CASTINGS:
12.1 It would be preferred that the approved sources of suspension tubes & other cast
components shall have their own RDSO approved captive foundries meeting Class „A requirements as per IS:12117 – 1996 (First revision)Reaffirmed 2017 or latest version and machining units.
12.2 In case, where the firms dont have their captive foundries, they shall fulfill the
following conditions:
They shall use castings from foundries certified Class „A as per IS: 12117 – 1996 (First revision)Reaffirmed 2017 or latest version only. The certification of foundry shall be, by RDSO and currently valid. The machinist firm shall furnish undertaking from casting manufacturer
showing long term commitment to supply castings to the machinist vendor. The Quality Assurance Plan (QAP) of the foundry shall formulate part of
approval process for the individual machinist vendor.
12.3 The QAP of the component shall clearly include the stipulation that “each cast component shall have individual distinct number embossed by the foundry so as to ensure its traceability”. A sample marking on suspension tube is given below:
At least two letter initial of the foundry + 2 digits of year of manufacturing code + 4 digits of unique serial number + at least 2 digits of customer code for the foundry. (Example: SMP/06/3991/SMP).
12.4 Stage inspection of all cast components shall be mandatory by the Inspecting Authority at the foundry premises. The QAP of the component shall clearly include such provision.
13.0 REQUIREMENT FOR FORGINGS:
13.1 Source of forging components shall be intimated to RDSO with infrastructure details. Firms shall have to furnish its guidelines / standard regulations against which they have approved the forging units as well as the units where manufacturing of the subject components takes place.
13.2 Heat treatment:
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 13 of 18
Forgings shall be supplied in ‘As forged’ or ‘As forged normalized’ condition (880ºC - 910ºC) to give the mechanical properties as per respective specification given in Clause 7.0 of this STR.
13.3 Freedom from defects:
The steel forgings shall be free from internal and surface defects such as seams, laps and injurious imperfections etc.
14.0 INSPECTION: 14.1 General inspection of the tube and components shall be in accordance with IS: 1387
– 1993 (Second Rev.) „General requirements for the supply of metallurgical materials.
14.2 Upon pre-arrangement, the purchaser shall have free entry at all time when work on
the contract of the purchaser is being performed to all parts of the manufacturers works which concern the manufacture of the material ordered under the specification. The manufacturer shall afford the inspector, free of charge, all reasonable facilities and necessary assistance to satisfy him that the material is being furnished in accordance with referred specifications. Final acceptance of all purchased material shall be made at purchasers premises.
15.0 SAMPLING FOR MECHANICAL TESTS: 15.1 Unless otherwise agreed, for the purpose of mechanical tests, the sample shall be
tested for each cast and heat treatment batch. 15.2 If the product is continuously heat treated, the sampling for mechanical tests shall
be as agreed to between the purchaser and the manufacturer.
16.0 MECHANICAL TESTS:
The test piece after being heat treated as per Clause 13.2 shall meet the following tests in the longitudinal direction upto a ruling section of 300 mm. Properties for thicker sections shall be subjected to agreement between the purchaser and the supplier.
16.1 Tensile Test:
The tensile test shall be carried out in accordance with IS: 1608(Part-1)- 1995 (Fourth revision) 2018 „Method for tensile testing of steel products or ASTM A370/05-19 or latest version.
16.2 Hardness:
The test pieces shall have Brinell hardness in accordance with IS: 1500(Part-1)(Fifth revision)- 1983 2019 or latest version „Method for brinell hardness test for metallic materials (Second Rev.).
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 14 of 18
16.3 Charpy Impact Value (V-Notch):
The test pieces shall show the minimum Charpy Impact values when tested as per IS: 1757(Part-1)- 1988 (Second Rev.) (Third revision)2014 or latest version „Method for Charpy impact test (V-Notch) for metallic materials.
16.4 Bend Test:
Bend test shall be carried out in accordance with IS: 1599- 1985 (Second Rev.) (fourth revision) 2019 or latest version Method for bend test for steel products other than sheet, strip, wire and tube).
17.0 OTHER SPECIAL TEST FOR SUSPENSION TUBE & ACCESSORIES: The tests to be carried out along with periodicity as mentioned below for ALCo & DEMU as well as HHP (EMD) tube & components; S. No. Testing Parameters Periodicity
Type test Acceptance
1 Radiography test Incoming Firms to declare 10% (Min.)
Finished 100% Firms to declare
2 Ultrasonic test Incoming Firms to declare Firms to declare
Finished 100% 100%
Incoming Firms to declare 4% (Min.)
Finished 100% Firms to declare
4 Dimensional measurements on CMM
Incoming Firms to declare Firms to declare
Finished 100% 20% (Min.)
17.1 Radiography test for Alco Loco & DEMU tube:
As per ASTM E446-15 or latest version, Level- III for Central portion & Level- II for both side housing bore of tube & as mentioned in the casting drg. no. 1/DCW/M/TM- 397, Alt.- latest.
17.2 Radiography test for HHP (EMD) Loco tube:
As per ETI 827 mentioned in casting drawing no. 40075432.
17.3 Ultrasonic test (UT):
This test shall be conducted as per ASTM A388-19 or latest version, 2007- for steel forgings & ASTM A609/ A609M-91-12 Reapproved 2018 (Reapproved 2007) for steel castings.
17.4 Magnaflux / Dye- Penetrant Test (DPT) shall be conducted by the manufacturer/
supplier. 17.5 Magnetic Particle Inspection (MPI) shall be conducted by the manufacturer/ supplier.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 15 of 18
18.0 TEST CERTIFICATES:
Three copies of test certificates shall be supplied unless otherwise stated on the order. The following details shall be furnished in the test certificate:
(i) Dimensional inspection (ii) Detail of heat treatment (iii) Chemical composition (iv) Results of mechanical tests (v) Results of additional tests called for in the drawing / order.
19.0 PACKING AND MARKING:
Suitably marked and finished MSU tube & components shall be packed to prevent corrosion and damage during transit. Machined surface shall be properly protected with anti-corrosive compounds.
20.0 Preference to make in India shall apply: The Government of India policy on “make in India “shall apply. 21.0 Vendor changes in approved status: All the provisions contained in RDSOs ISO
procedures laid down in document no. QO-D-8.1-11, dated 01.07.2020(Titled “Vendor –changes in approved status) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vendor/vendors in the contracts floated by Railways to maintain quality of products supplied to Railways.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 16 of 18
ANNEXURE - I
MACHINERY & PLANT (M&P) FOR MANUFACTURING The following is the list of typical machining facilities mandatory with the firm: 1. The manufacturer shall have CNC Horizontal Machining Center (HMC) and CNC
turning center of requisite accuracy suitable for the suspension tube & components as per drawings mentioned in clause 7.0
2. Marking / measuring table of suitable size.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 17 of 18
LIST OF MEASURING MACHINES & INSTRUMENTS:
The following is the mandatory list of measuring facilities to be available with the firm:
1. Calibration of the Testing / Measuring Equipments shall mandatorily be done at least once in a year unless stated otherwise for Vernier Calipers, Micrometers, Inside & Outside Calipers and all other Gauges required during matching operations and dimensional checks.
2. It shall be mandatory for the new manufacturers to have open bridge type Co- ordinate Measuring Machine (CMM) of requisite accuracy in accordance with the dimensions of the jobs i.e. suspension tube & components etc. to be measured in a single set up. However, the existing manufacturers can continue with the facilities as available at the time of prototype test.
3. Micrometer (outside).
5. Bore Dial Gauge.
6. Vernier Height Gauge.
7. Thread plug gauges for checking threading portion duly calibrated.
8. Hard and ground pins to check accuracy of hole dia. of pole shoes fixing bolts.
9. Fixtures shall be available (mandatory):
Facilitate to check accuracy of GWE & RWE side bores, co-axiality, parallelity, perpendicularity in respect of rotor fixing end shields bore along with GWE & RWE side bores.
Facilitate to check and prove that air-gap has been maintained for all the pole faces. The fixture shall be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore.
Facilitate to check clearance between the bore of suspension tube and diameter of axle ( To avoid fitment problem during assembly at workshop ( M/s SMPL supplied 47 nos suspension tube was rejected by DLW due to infringement problem seen during their assembly). The fixture shall be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore.
The gauges shall be hard and ground to avoid any lapses of accuracy.
10. Calibrated template to check the centre of both poles.
11. Infra-red thermometer for checking temperature of material at standard room before dimensional checking.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 18 of 18
LIST OF TESTING FACILITIES:
1.0 Calibration of the Testing / Measuring Equipments shall be done at least once in a year, unless stated otherwise.
2.0 Inspection Staff conducting non-destructive testing shall be adequately trained and qualified by recognized agency and shall have adequate experience.
3.0 Staff conducting tests like Chemical Analysis and Mechanical Properties shall have adequate skill & competence and shall have under gone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests on blind samples.
4.0 Following testing facilities shall be available with the firm; alternately the test can also be conducted through NABL or Govt. approved lab. This same shall be indicated in the QAP.
4.1 METALLURGICAL AND CHEMICAL LABORATORY:
1. Availability of Emission Spectrometer with necessary standard and automatic printer shall be preferred for verification of chemical composition of material.
2. Suitable Radiography / Ultrasonic testing facilities. 3. Magnaflux / Dye-Penetrant Test (DPT) facilities for checking of surface cracks. 4. Magnetic Particle Inspection (MPI) facilities for checking sub-surface flaws. 5. Metallurgical Microscope with magnification power upto 500x & metallographic
sample preparation facilities with appropriate accessories to take photographs of slides.
4.2 PHYSICAL LABORATORY:
1. Universal Testing Machine of 40 tonne capacity with graphical recording facilities for conducting tensile tests.
2. Direct reading Hardness Tester of capacity 95-500 BHN.
3. Impact Testing Machine (Charpy V- Notch) of 0-300 Joules capacity for conducting impact test with facilities for notch cutting and undertaking this test at sub-zero temperatures as per the specified standard.
Tubes with components for BG Diesel –Electric Locomotives (ALCo & HHP Locos) and
DEMUS.
STR No. : MP.STR.EM-01.01.12((Revision-02), July’2020.
1. RDSO is reviewing the specification/STR to cater to the latest technological developments in
the field, modify clauses not relevant in the present context and making them more enabling
with focus on functional requirements.
2. It is requested that your comments / suggestions with regard to improvements /modifications
in specification / STR of the above mentioned item may be submitted in the following format
along with the justification for the changes required.
Part A: Basic Information
5 Address for Correspondence
6 Contact No.
7 Email ID
8 Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item
9 Whether any technical document/Report/Study to support suggested changes is available / enclosed for better appreciation
Part B: Comments / Suggestions on the specification
SN Clause No. of RDSO STR/ Spec
Clause, as it exists in RDSO STR/ Spec
Clause , as it should read after incorporation of comments /suggestions in the RDSO Spec / STR
Justification for changes
Comments may be sent to following address within one month from the date of publication on
rdso.indianrailways.gov.in
Manak Nagar, Lucknow – 226011
GOVERNMENT OF INDIA MINISTRY OF RAILWAYS
( )
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO & HHP LOCOS) & DEMUS.
...-..(-),-
STR.NO.MP.STR.EM-01.01.12 (Revision -02),July 2020
ekud uxj] y[kuÅ - 226 011
RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226 011
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 2 of 18
LIST OF AMENDMENTS
No
STR No. MP.STR.EM-01.01.12(Rev-02) of July 2020
1
Clause 5.1 IS:1030,IS:1387,IS:2062,
IS:1757,IS: 3739 & IS: 4897
ASTM A370/05, ASTM A388,
Latest version of amendment &
& BS:1486 Latest version of
added
added
Latest version added.
14 Clause 20 Preference to make in India shall
apply added
added (Vendor changes in
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 3 of 18
-- AMENDMENT HISTORY 1
4.0 QUALITY CONTROL ORGANIZATION 4
5.0 GOVERNING SPECIFICATIONS 4-5
6.0 INCOMING MATERIAL 6
9.0 QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN 9
10.0 CHEMICAL COMPOSITION 10
11.0 MATERIAL SPECIFICATION 10
14.0 INSPECTION 11
16.0 MECHANICAL TESTS 12
18.0 TEST CERTIFICATES 13
-- MACHINERY & PLANT (M&P) FOR MANUFACTURING (ANNEXURE-I) 14
-- LIST OF MEASURING MACHINES & INSTRUMENTS (ANNEXURE-II) 15
-- LIST OF TESTING FACILITIES (ANNEXURE-III) 16
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 4 of 18
REVISED SCHEDULE OF TECHNICAL REQUIREMENTS FOR
TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL- ELECTRIC LOCOMOTIVES (ALCO & HHP BOTH) AND DEMUs
1.0 SCOPE:
The Motor Suspension Unit (MSU) tubes are vital parts of traction motors used on Alco and HHP diesel electric locomotives as well as DEMU of Indian Railways. These components are procured by DLW, DMW and Zonal Railways from RDSO approved sources as per DLW, DMW & BHEL/CGL drawings. In addition, a number of assembly components are also procured as per DLW, DMW & BHEL/CGL drawings. The schedule of technical requirement (STR) mentioned hereunder is being issued to serve as a guide to manufacturers and shall be read in conjunction with the relevant drawings. The firms shall satisfy themselves to having complied with, all the requirements of the drawings and STR. Approval shall be granted to a firm that has the capability to supply fully machined suspension tube as per the STR. ( This STR supersedes earlier issued RDSOs STR No. MP.01.01.12Rev-01) July 2019)
2.0 GENERAL REQUIREMENTS:
2.1 The firm shall have valid ISO-9001-2015 certification issued by an approved agency with the activity desired clearly mentioned in the scope of certification. The firm shall have a Quality Manual indicating the extent of control over production.
2.2 A system of regular submission of rejection details of material giving rejection rate, cause of rejection, corrective action taken etc. on quarterly basis shall be followed by the firm.
2.3 The firm shall have a system of documentation with respect to rejection at customer end, warranty replacement and failure of item supplied by them during service.
2.4 The firm shall have a system of recording the plant, machinery and control equipments remaining out of service, nature of repairs done etc.
2.5 The testing and measuring equipment shall be duly calibrated and the validity of calibration shall be current and verified by physically checking the calibration certificate issued by the Calibration Agency from where it was calibrated.
2.6 The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage.
2.7 At the time of application, the firm must submit clause wise compliance of this STR.
3.0 QUALITY ASSURANCE PLAN (QAP):
The firm shall prepare a Quality Assurance Plan (QAP) for all items for which approval is sought and submit the same as a part of compliance of this STR. The
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 5 of 18
QAP shall be a comprehensive document covering the following aspects including all the parameters in accordance with ISO Document No. QM-RF-8.1-3, Version No. 1.0 or latest - Guidelines for preparing QAP during registration. (i) Details of Quality Control Organization of the firm along with key personnel
engaged in the QC function. (ii) Quality Assurance Process of incoming materials used for the subject items. (iii) Process Flow Chart indicating process of manufacture of an individual product
or for a family of products, if the process is same. (iv) Quality Assurance System – Inspection & Testing Plan including stage
inspection. (v) Calibration scheme and status of calibration of equipments used in the quality
process.
Details of the above aspects are described in the following paragraphs. The QAP shall be approved by RDSO and shall form basis of approval process.
3.1 Firm shall have to declare details of the manufacturing operations to be conducted
in house or by outside agencies. Details of the outside agencies shall be indicated and prior approval shall be taken from RDSO, which reserves the right to inspect these firms also.
A general format for guidance is given below:
Product / Name of the process and details of machine used indicating their capacities / accuracy limit
Acceptance limit of the parameters to be inspected during different operations of MSU Tube and components
Standards followed for acceptance of the test parameters
Sample size & its frequency of inspection
Format no. for recording for traceability
Action taken on rejection, if any
Calibration scheme and status of calibration of equipments used in the quality control process
4.0 QUALITY CONTROL ORGANIZATION: 4.1 The complete organizational setup of the quality control key personnel and officials
along with their qualification and experience shall be furnished. 4.2 The Quality Control Organization shall be headed by a senior level official having
adequate technical qualification who shall directly report to plant in-charge.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 6 of 18
5.0 GOVERNING SPECIFICATIONS:
The latest revisions as applicable to the specification referred below shall be followed.
5.1 For materials: (i) IS: 1030-1998 (5th Rev.) Reaffirmed 2017 or latest version - “Carbon steel castings
for general engineering purposes- specification”. (ii) IS: 1387-1993 (Second Rev.) Reaffirmed 2018 or latest version - “General
requirements for the supply of metallurgical materials”. (iii) IS: 2062-1999 2011 (7th Revision),Reaffirmed 2018 or latest version Steel for general
structural purposes – Specification (Fifth Rev.). (iv) IS: 2269- 1995,2006(5th Revision ) Reaffirmed 2016 or latest version Specification for
Hexagon socket head screws. (v) IS: 5517-1993(2nd Revision), Reaffirmed 2019 or latest version Steels for hardening
and tempering – Specification. (vi) IS: 12117 – 1996(1st Revision) Reaffirmed 2017 or latest version : Norms for
classification of Steel Foundries for quality assurance (First Rev.), Feb.2002. (vii) ISO: 9001- 2000 2015: Purchasing Procedure. (viii) BS: 1486 Part-II 1961( or latest version) for Zinc Plated Grease Nipple. (ix) ASTM A513 – 20 or Latest version Steel Tubing. (x) ASTM A519-17 or Latest version – Hot finished seamless tubing. 5.2 For tests: (i) IS: 1500(Part-1)(5th Revision )1983 2019or latest version „Method for Brinell
hardness test for metallic materials (Second revision). (ii) IS: 1599 - 1985 (Second Rev.) 4th revision 2019 or latest Method for bend test for
steel products other than sheet, strip, wire and tube). (iii) IS: 1608(Part-1) - 1995 (Second Rev.)(4th Revision 2018 or latest „Method for tensile
testing of steel products. (iv) IS: 1757(Part-1) - 1988 (Second Rev.) 3rd revision 2014 or latest version „Method for
Charpy Pendulum impact test (V-Notch) for metallic materials. (v) ASTM A370/05 -19 or latest version Tensile Test. (vi) ASTM A388, 2007- 19 or latest Ultrasonic Test for steel forgings. (vii) ASTM A609/A609M- 91-12 (Reapproved 2007 2018) or latest - Ultrasonic Test for
steel castings. (viii) ASTM E446 -15 or latest version - Radiography test Level- III for central portion and
Level- II for both side housing bores. 5.3 For dimensional tolerances: (i) IS: 3739-1987 (First Rev.) Reaffirmed 2018 - Dimensional tolerances for carbon and
constructional steel products. (ii) IS: 4897- 1994(3rd Revision) Reaffirmed 2017or latest version Deviations on
untoleranced dimensions and mass of steel castings.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 7 of 18
5.4 For welding:
A.I 1651- EMD welding, brazing and soldering specification. 6.0 INCOMING MATERIAL: 6.1 A complete Bill of Material (BOM) indicating all input material required for
manufacturing of the product, governing specification and their sources of supplies as approved by the firm in accordance with clause 7.4.1 of ISO:9001 (2000) shall be furnished.
6.2 Test results of incoming raw material with reference to test certificate issued by the
supplier and the results of internal tests carried out by the firm for verification shall be submitted as a part of QAP.
7.0 DIMENSIONS AND TOLERANCES:
The MSU tube and components shall conform to the respective drawings indicated for dimensions, tolerances, finish and material etc.:
7.1 List of drawings of Suspension Tube & Accessories (10 Components) for traction motor type TM 4907 application (Class of locos WDM3A & WDG3A):
Sl. no.
1/DCW/M/TM- 398, Alt- W
Casting - Carbon Steel- IS: 1030-1998 (Fifth Rev.) Reaffirmed 2017 or latest version, Gr. 280-520W.
2 Bearing Housing for TM 4907
1/DCW/M/TM- 414, Alt- Nil
3 End Cover (RWE) for TM 4907
1/DCW/M/TM- 416, Alt-Nil
Forging - IS: 5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
4 End Cover (GWE) for TM 4907
1/DCW/M/TM- 417, Alt-Nil
Forging - IS: 5517-1993 :(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
5 Abutment Piece for TM 4907
1/DCW/M/TM- 418, Alt-Nil
Forging - IS: 5517-1993 :(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
6 Enclosure for TM 4907
1/DCW/M/TM- 419, Alt-Nil
Forging - IS: 5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.
7 Adjustment Washer for TM 4907
1/DCW/M/TM- 415, Alt-Nil
IS: 2062- 1999 7th revision 2011 (Reaffirmed 2016)for Steel Plate Gr- B.
8 Socket Head Screw M10 x 30 long
4/DCW/M/TM- 421, Alt-Y
IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 8 of 18
4/DCW/M/TM- 423, Alt-Y
IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version
10 Socket Head Screw M12 x 90 long
4/DCW/M/TM- 422, Alt-Y
IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version
11 Grease Nipple 4/DCW/M/TM- 420, Alt-Nil
BS: 1486 Part-II 1961 (Zinc Plated). or latest version
7.1.1 In case cast components (i.e. item at sl. no. 2 to 6 mentioned above) are chosen as
per clause 11.2, then the material shall be Carbon Steel- IS: 1030-1998 (Fifth Rev.) Reaffirmed 2017 or latest version, Gr. 280-520W.
7.1.2 Hardwares as per item no. 8 to 11 of clause 7.1 if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturers to be declared in the QAP. (If sources are not specified in the relevant drawings)
7.2 Housing Bearing Kit for HHP Loco (consisting of 11 items) as per DLW Part
No 17454499 & DGR. No. K- 1745037 Alt. ‘e’:
S. No.
Material Specifications and Tests
1 Housing Bearing Machine
17020864 / 40075563 Alt. „d or latest.
EMS 15 – Cast Steel as per casting drawing no. 40075432. A.I 1651- Weld Braze Specification mentioned in drawing no. 40075563.
2 Cap (CE) Axle Bearing Mach.
17250626 / 40086808 Alt.
„c or latest.
Material as per casting drawing no. 40076800: Casting- EMS 9 Nodular Iron and ETI 827 or Plate - MS 4361 steel.
3 Cap PE Axle Bearing Mach.
17250365 / 40076796 Alt. „b or latest.
Material as per casting drawing no. 40076797: Casting- EMS 9 Nodular Iron and ETI 827 or Plate - MS 4361 steel.
4 Seal PE 17250493 / 40076794 Alt. „b or latest.
Material as per casting drawing no. 40076795: Tubing- ASTM A519-17 or latest version or latest version Hot finished seamless tubing or Plate - MS 4361 steel.
5 Spacer CE 17087636 / 40076798 Alt. „b or latest.
ASTM A513-20 or latest version Type 5 (DOM) Steel Tubing as per drawing no. 40076798.
6 Seal 17271472 / 40076990 Alt. „b or latest.
Nitrile (Buna-N) as per drawing no. 40076990.
7 Seal 17271496 / 9084265 Alt. „c
or latest.
8 Plug 1/8 PT 17300083 / 8348617 Alt. „Ba or latest.
Steel as per drawing no. 8348617.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 9 of 18
9 Plug 3/8 PT 17300010 / 8348619 Alt. „Ba or latest.
Steel as per drawing no. 8348619.
10 Screw Hexagon Socket Head Cap
19250010- 138293 Alt. „g
or latest.
Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C37- 45 as per drawing no. 138293.
11 Screw Hexagon Socket Head Cap
19250022- 138299 Alt. „Bc
or latest.
Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C37- 45 as per drawing no. 138299.
7.2.1 Hardwares as per item no. 8 to 11 of clause 7.2, if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturer as recommended in the DLW drawing no. K- 1745037 of Housing Bearing Kit.
7.2.2 Nitrile seals as per item no. 6 & 7 of clause 7.2, if not manufactured by the supplier itself, shall be out sourced from reputed manufacturers already approved with RDSO for similar items. The sources shall be declared in the QAP.
7.3 Housing Bearing Kit for HHP Loco (consisting of 4 items) as per DLW Part
No. 17454487 & DRG. No. K-1745036 Alt. ‘c’:
S. No.
Material Specifications and Tests
„a or latest
2 Cover Assembly
17250390 / 40012764 Alt. „Ab or latest
MS 4361 Steel as per drawing no. 40012026 for Cover-GR Case AY- Mach.
3 Tube 17203510 / 40076189 Alt. „Bb or latest
ASTM A513-20 or latest version Type 5 (DOM) Steel Tubing as per drawing no. 40076189.
4 Ring 17043980 / 40076190 Alt. „Ab or latest
MS 4361 Steel as per drawing no. 40076190.
7.4 List of drawings of Suspension Tube & Accessories for traction motor type TM 4303 / C1005TM application (1400 HP DEMU):
S. No.
1 General Arrangement Axle Suspension Unit.
04391580002 (Latest) CGM/106001 (Latest) 1
2 Roller bearing suspension tube
04391580001 (Latest) CGM/106801 (Latest) 1
3 Bearing Housing 14451575001 (Latest) CGM/206803 (Latest) 1
4 Adjustment Washer 14451575002 (Latest) CGM/206805 (Latest) 1
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 10 of 18
7 Abutment Piece 14451575004 (Latest) CGM/206804 (Latest) 1
8 Enclosure 14391580001 (Latest) CGM/206801 (Latest) 1
9 Socket Head Screw (M10 x 30 Long)
44391560001 (Latest) CGM/42201 (Latest) 6
10 Socket Head Screw (M12 x 70 Long)
44391560003 (Latest) CGM/42202 (Latest) 16
11 Socket Head Screw (M30 x 110 Long)
-- CGM/406801 (Latest) 8
13 Spring Washer A30 -- CGM/32204 (Latest) 8
The manufacturer shall supply suspension tube & components for DEMU application as per the details & drawings provided above or by the purchaser. Quality control aspects of the tube & components shall conform to this STR.
7.4.1 Hardwares as per item no. 9 to 13 of clause 7.4 if not manufactured by the supplier itself, shall be out sourced from reputed brand / manufacturers to be declared in the QAP. (If sources are not specified in the relevant drawings).
8.0 PROCESS OF MANUFACTURE: 8.1 Complete process flow chart covering all steps of process of manufacture for an
individual product (or for a family of products, if the process is same) shall be clearly enlisted as a part of QAP.
8.2 The following details of machines used for all the steps of machining operations
shall be included:
Make and Model of the machine Accuracy. Details of machining operations.
8.3 Machining process shall be such that all critical dimensions are final machined on
CNC machining centers, preferably in single setting. 8.4 Details of Jigs and Fixtures used during manufacture shall be furnished along with
the manufacturing process, wherever used. 8.5 List of typical machinery & plant (M&P) required for manufacture is furnished in
Annexure- I. The list is for general guidance only and actual manufacturing operations shall be submitted and got approved by the firm as a part of QAP.
9.0 QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN:
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 11 of 18
9.1 Complete inspection and testing chart covering all steps of process of manufacture for an individual product including final inspection shall be clearly enlisted as a part of QAP.
9.2 The following details of measuring instruments / equipments / jigs / fixtures used for all the steps of measurement operations shall be included: Make and Model of the measuring equipment Accuracy Value to be measured and acceptable value range
9.3 Stage inspection detailing inspection procedure, inspection parameters and method
of testing/ test procedure including sample sizes for destructive and non-destructive testing. Record of test results of stage inspection shall be available and furnished where needed.
9.4 The list of measuring machines / instruments & testing facilities are furnished in
Annexure- II & III respectively for general guidance only. However, the specific testing and measuring instruments, gauges used by the firm will also form part of QAP, which shall be submitted and got approved by the firm.
9.5 Dimensional measurements shall be made on three-dimensional co-ordinate
measurement machines as mentioned in Annexure – II on prototype & on sample lots. Periodicity of measurement shall be as indicated in clause 17.0 (Sl. no.4) of the STR. Measurements shall be included as a part of QAP.
10.0 CHEMICAL COMPOSITION: The permissible variation in chemical composition and ladle analysis of steel shall
conform to the respective requirements given in Clause 7.0 of this STR. 11.0 MATERIAL SPECIFICATION: 11.1 General requirements relating to the supply of material shall conform to IS: 1387-
1993 (Second Rev.) Reaffirmed-2018 or latest version „General requirements for the supply of metallurgical materials, as per Clause 5.1 (ii) of this STR.
11.2 The material used for cast or forged components shall be so chosen that none of the
specified properties in this STR is compromised. 11.3 The suspension tube shall only be manufactured from castings supplied by RDSO
approved Class “A” foundries. 11.4 The suspension tube components i.e. accessories or any other components shall be
manufactured from normalized carbon steel castings or forgings as applicable & mentioned in Clause 7.0 of this STR.
11.5 In case the manufacturer proposes to supply forged suspension tube components
instead of cast components, the same can be accepted only with the prior approval
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 12 of 18
of RDSO. The forging shall be manufactured from killed steel produced by open hearth furnace, electric furnace or any other approved process.TC
11.6 Rough machining of the forgings shall be carried out in case of procurement of
forgings by the purchaser & forging shall be supplied to the dimensions specified in the drawing of rough machined components to be provided by the purchaser.
11.7 In case, finished component is procured by the purchaser, machining shall be done
in suitable sequence approved by the purchaser. 12.0 REQUIREMENT FOR CASTINGS:
12.1 It would be preferred that the approved sources of suspension tubes & other cast
components shall have their own RDSO approved captive foundries meeting Class „A requirements as per IS:12117 – 1996 (First revision)Reaffirmed 2017 or latest version and machining units.
12.2 In case, where the firms dont have their captive foundries, they shall fulfill the
following conditions:
They shall use castings from foundries certified Class „A as per IS: 12117 – 1996 (First revision)Reaffirmed 2017 or latest version only. The certification of foundry shall be, by RDSO and currently valid. The machinist firm shall furnish undertaking from casting manufacturer
showing long term commitment to supply castings to the machinist vendor. The Quality Assurance Plan (QAP) of the foundry shall formulate part of
approval process for the individual machinist vendor.
12.3 The QAP of the component shall clearly include the stipulation that “each cast component shall have individual distinct number embossed by the foundry so as to ensure its traceability”. A sample marking on suspension tube is given below:
At least two letter initial of the foundry + 2 digits of year of manufacturing code + 4 digits of unique serial number + at least 2 digits of customer code for the foundry. (Example: SMP/06/3991/SMP).
12.4 Stage inspection of all cast components shall be mandatory by the Inspecting Authority at the foundry premises. The QAP of the component shall clearly include such provision.
13.0 REQUIREMENT FOR FORGINGS:
13.1 Source of forging components shall be intimated to RDSO with infrastructure details. Firms shall have to furnish its guidelines / standard regulations against which they have approved the forging units as well as the units where manufacturing of the subject components takes place.
13.2 Heat treatment:
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 13 of 18
Forgings shall be supplied in ‘As forged’ or ‘As forged normalized’ condition (880ºC - 910ºC) to give the mechanical properties as per respective specification given in Clause 7.0 of this STR.
13.3 Freedom from defects:
The steel forgings shall be free from internal and surface defects such as seams, laps and injurious imperfections etc.
14.0 INSPECTION: 14.1 General inspection of the tube and components shall be in accordance with IS: 1387
– 1993 (Second Rev.) „General requirements for the supply of metallurgical materials.
14.2 Upon pre-arrangement, the purchaser shall have free entry at all time when work on
the contract of the purchaser is being performed to all parts of the manufacturers works which concern the manufacture of the material ordered under the specification. The manufacturer shall afford the inspector, free of charge, all reasonable facilities and necessary assistance to satisfy him that the material is being furnished in accordance with referred specifications. Final acceptance of all purchased material shall be made at purchasers premises.
15.0 SAMPLING FOR MECHANICAL TESTS: 15.1 Unless otherwise agreed, for the purpose of mechanical tests, the sample shall be
tested for each cast and heat treatment batch. 15.2 If the product is continuously heat treated, the sampling for mechanical tests shall
be as agreed to between the purchaser and the manufacturer.
16.0 MECHANICAL TESTS:
The test piece after being heat treated as per Clause 13.2 shall meet the following tests in the longitudinal direction upto a ruling section of 300 mm. Properties for thicker sections shall be subjected to agreement between the purchaser and the supplier.
16.1 Tensile Test:
The tensile test shall be carried out in accordance with IS: 1608(Part-1)- 1995 (Fourth revision) 2018 „Method for tensile testing of steel products or ASTM A370/05-19 or latest version.
16.2 Hardness:
The test pieces shall have Brinell hardness in accordance with IS: 1500(Part-1)(Fifth revision)- 1983 2019 or latest version „Method for brinell hardness test for metallic materials (Second Rev.).
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 14 of 18
16.3 Charpy Impact Value (V-Notch):
The test pieces shall show the minimum Charpy Impact values when tested as per IS: 1757(Part-1)- 1988 (Second Rev.) (Third revision)2014 or latest version „Method for Charpy impact test (V-Notch) for metallic materials.
16.4 Bend Test:
Bend test shall be carried out in accordance with IS: 1599- 1985 (Second Rev.) (fourth revision) 2019 or latest version Method for bend test for steel products other than sheet, strip, wire and tube).
17.0 OTHER SPECIAL TEST FOR SUSPENSION TUBE & ACCESSORIES: The tests to be carried out along with periodicity as mentioned below for ALCo & DEMU as well as HHP (EMD) tube & components; S. No. Testing Parameters Periodicity
Type test Acceptance
1 Radiography test Incoming Firms to declare 10% (Min.)
Finished 100% Firms to declare
2 Ultrasonic test Incoming Firms to declare Firms to declare
Finished 100% 100%
Incoming Firms to declare 4% (Min.)
Finished 100% Firms to declare
4 Dimensional measurements on CMM
Incoming Firms to declare Firms to declare
Finished 100% 20% (Min.)
17.1 Radiography test for Alco Loco & DEMU tube:
As per ASTM E446-15 or latest version, Level- III for Central portion & Level- II for both side housing bore of tube & as mentioned in the casting drg. no. 1/DCW/M/TM- 397, Alt.- latest.
17.2 Radiography test for HHP (EMD) Loco tube:
As per ETI 827 mentioned in casting drawing no. 40075432.
17.3 Ultrasonic test (UT):
This test shall be conducted as per ASTM A388-19 or latest version, 2007- for steel forgings & ASTM A609/ A609M-91-12 Reapproved 2018 (Reapproved 2007) for steel castings.
17.4 Magnaflux / Dye- Penetrant Test (DPT) shall be conducted by the manufacturer/
supplier. 17.5 Magnetic Particle Inspection (MPI) shall be conducted by the manufacturer/ supplier.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 15 of 18
18.0 TEST CERTIFICATES:
Three copies of test certificates shall be supplied unless otherwise stated on the order. The following details shall be furnished in the test certificate:
(i) Dimensional inspection (ii) Detail of heat treatment (iii) Chemical composition (iv) Results of mechanical tests (v) Results of additional tests called for in the drawing / order.
19.0 PACKING AND MARKING:
Suitably marked and finished MSU tube & components shall be packed to prevent corrosion and damage during transit. Machined surface shall be properly protected with anti-corrosive compounds.
20.0 Preference to make in India shall apply: The Government of India policy on “make in India “shall apply. 21.0 Vendor changes in approved status: All the provisions contained in RDSOs ISO
procedures laid down in document no. QO-D-8.1-11, dated 01.07.2020(Titled “Vendor –changes in approved status) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vendor/vendors in the contracts floated by Railways to maintain quality of products supplied to Railways.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 16 of 18
ANNEXURE - I
MACHINERY & PLANT (M&P) FOR MANUFACTURING The following is the list of typical machining facilities mandatory with the firm: 1. The manufacturer shall have CNC Horizontal Machining Center (HMC) and CNC
turning center of requisite accuracy suitable for the suspension tube & components as per drawings mentioned in clause 7.0
2. Marking / measuring table of suitable size.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 17 of 18
LIST OF MEASURING MACHINES & INSTRUMENTS:
The following is the mandatory list of measuring facilities to be available with the firm:
1. Calibration of the Testing / Measuring Equipments shall mandatorily be done at least once in a year unless stated otherwise for Vernier Calipers, Micrometers, Inside & Outside Calipers and all other Gauges required during matching operations and dimensional checks.
2. It shall be mandatory for the new manufacturers to have open bridge type Co- ordinate Measuring Machine (CMM) of requisite accuracy in accordance with the dimensions of the jobs i.e. suspension tube & components etc. to be measured in a single set up. However, the existing manufacturers can continue with the facilities as available at the time of prototype test.
3. Micrometer (outside).
5. Bore Dial Gauge.
6. Vernier Height Gauge.
7. Thread plug gauges for checking threading portion duly calibrated.
8. Hard and ground pins to check accuracy of hole dia. of pole shoes fixing bolts.
9. Fixtures shall be available (mandatory):
Facilitate to check accuracy of GWE & RWE side bores, co-axiality, parallelity, perpendicularity in respect of rotor fixing end shields bore along with GWE & RWE side bores.
Facilitate to check and prove that air-gap has been maintained for all the pole faces. The fixture shall be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore.
Facilitate to check clearance between the bore of suspension tube and diameter of axle ( To avoid fitment problem during assembly at workshop ( M/s SMPL supplied 47 nos suspension tube was rejected by DLW due to infringement problem seen during their assembly). The fixture shall be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore.
The gauges shall be hard and ground to avoid any lapses of accuracy.
10. Calibrated template to check the centre of both poles.
11. Infra-red thermometer for checking temperature of material at standard room before dimensional checking.
SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL–ELECTRIC LOCOMOTIVES (ALCO &
HHP LOCOS) & DEMUS. STR NO.MP STR.EM-01.01.12(REV.-02)JULY 2020
Page 18 of 18
LIST OF TESTING FACILITIES:
1.0 Calibration of the Testing / Measuring Equipments shall be done at least once in a year, unless stated otherwise.
2.0 Inspection Staff conducting non-destructive testing shall be adequately trained and qualified by recognized agency and shall have adequate experience.
3.0 Staff conducting tests like Chemical Analysis and Mechanical Properties shall have adequate skill & competence and shall have under gone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests on blind samples.
4.0 Following testing facilities shall be available with the firm; alternately the test can also be conducted through NABL or Govt. approved lab. This same shall be indicated in the QAP.
4.1 METALLURGICAL AND CHEMICAL LABORATORY:
1. Availability of Emission Spectrometer with necessary standard and automatic printer shall be preferred for verification of chemical composition of material.
2. Suitable Radiography / Ultrasonic testing facilities. 3. Magnaflux / Dye-Penetrant Test (DPT) facilities for checking of surface cracks. 4. Magnetic Particle Inspection (MPI) facilities for checking sub-surface flaws. 5. Metallurgical Microscope with magnification power upto 500x & metallographic
sample preparation facilities with appropriate accessories to take photographs of slides.
4.2 PHYSICAL LABORATORY:
1. Universal Testing Machine of 40 tonne capacity with graphical recording facilities for conducting tensile tests.
2. Direct reading Hardness Tester of capacity 95-500 BHN.
3. Impact Testing Machine (Charpy V- Notch) of 0-300 Joules capacity for conducting impact test with facilities for notch cutting and undertaking this test at sub-zero temperatures as per the specified standard.